Extrusion molding machine



Jan. 8, 1952 c. c. MISFELDT EXTRUSION MOLDING MACHINE 6 Sheets-Sheet 1 Filed June.20, 1944 INVENTOR. CHARLEs C M/SFELDT Jan. 8, 1952 cc. MISFELDT EXTRUSION MOLDING MACHINE 6 Sheets-Sheet 2 Filed June 20, 1944 \DN DON wk v\\ @k N INVENTOR.

m R WQQQQu mm Qm 674421.55 C. M/SFELDT Jan. 8, 1952 c. c. MISFELDT 2,531,550

EXTRUSION MOLDING MACHINE Filed June 20, 1944 6 Sheets-Sheet 3 INVENTOR.

firraF/VIVJ x f w nunnuunufll l nu NW HHHHHHHHHHHHHHHHHMT QHHN lhvl h N v Vi w? in CHARLES C. MISFEL 07' BY Jan. 8, 1952 c. c. MISFELDT 2,581,550

EXTRUSION MOLDING MACHINE Filed June 20, 1944 FIE-T 6 Sheets-Sheet 4 WEIGHT F E-JF V INVENTOR.

CHAELEs C MISFELDT BY array/V575 Jan. 8, 1952 c. c. MISFELDT 2,581,550

EXTRUSION MOLDING MACHINE Filed June 20, 1944 6 Sheets-Sheet 5 BLED ' ,INVENTOR. CHAR/.55 C MISFELDT Jan. 8, 1952 c. c. MISFELDT EXTRUSION MOLDING MACHINE 6 Sheets-Sheet 6 Filed June 20, 1944 INVENTOR. CHARLES C. MISFELDT BY W" flrrakfi rys Patented Jan. 8, 1952 UNITED STATES PATENT OFFICE EXTRUSION MOLDING MACHINE Charles 0. Misfeldt, Chicago, 111.

Application June20, 1944, Serial No. 541,135 9 Claims. (01. 18-30) M-y invention relates to a machine for making extrusion moldings of metal which have many of the characteristics of drop forgings and which are formed by extrusion and molding forces applied to plastic metal. The product of the machine will herein be known as moldedextrusions as distinguished from ordinary extrusions, die castings, drop forgings, or simila products.

This application is a continuation in part of my application for Extrusion-Molding Method, Serial No. 406,254, filed August 11, 1941, now patent No. 2,356,338 of August 22, 1944.

Two problems are prominentin the production of die castings having hightensile strength, In die casting, the metal is forced while molten. into a mold, through asmall gate or group of small gates under pressure, and is held. in the mold under relatively low pressure while the metal solidifies, the gate being so small that the pressure is prevented from reaching the mold by metal freezing at the small gate. Great improvements have taken place in the die casting art, but even today great care must be taken to avoid inclusions or gas pockets and shrinkage in the final castings. Also it is difiicult to make the castings out of metal so that the final casting will have sufiicient tensile strength for many uses for which such castings might be desired. Furthermore, die castings which solidify from the molten state into the solid state while" in the mold, have relatively large grain size in the core or center of the casting while the surface isfine grain size because of the chilling effect ofv the metal surface of the die; and because of porosity and shrinkage, subsequent heat treatment cannot be applied without resulting blisters and warping. Such castings still do not have sum cient tensile strength or density, for many uses, Die castings" also have a large shrinkage factor, both internal and dimensional, causing stresses to be set up internally and are inclined to grow and Warp in use or when machine finishes are added.

Another method of producing an i'rregulararticle is by drop forging; The heated metal is placed over a die or between two dies, an'd'then hammered into shape by repeated blows. Such drop forgings have excellent tensile characteristics, but are expensive, as the drop forging procedure does not lend itself readily to high quantity production of the articles, and because there is so much machine work to be done to finish the forged p'artjto accurate dimensions. such a forged article has only a: rough finish.

The means and method to be described herein produce a product in a manner only generally similar to the manner of producing die castings. This product, however, when removed from the mold has some of the general characteristics of a drop forging or an extrusion with related tensile strength,- yield strength, and modulus of elasticity, such characteristics having been 1mparted to the product by the use of a novel method and machine for making a product which is free from fiow lines, slip planes and concentrationiof dense wo'rke'd portions, such as are "typical of forging and extrusion operations by conventional practices, as will hereinafter be apparent.

Therefore, among the objects of my invention are: To provide a means for producing parts or articles by extruding and molding material thereby giving them the physical characteristics of drop forgings and of wrought material; to provide a means for controlling the grain structure of the product; to provide a means producing fine grain, pressure molded castings of high tensile strength; to provide a machine for extruding and molding a metal to form a molded extrusion; to provide a molded extrusion which has high tensile and: yield strength, and high modulus of elasticity and adaptability for uses that cannot be adequately satisfied by die castings or sand castings in the finished or semifinished condition; to provide a means" for making' a molded article of metal or other material; to provide molded metal items of uniform grain structurethroughout; to provide a means for making apressure forging without repeated blows; to provide a means producing pressure forging's in quantity and with uniformity of grade and to finished dimensions; to provide a means for producing extrusions, molded to a combination of contours and shapes; to provide a means for producing wrought parts that can be machin'e'd without distortion; to provide a means therefore to be understood" that my method is Fig. 2 is a fragmentary view showing a means 1 for using molten metal or semi-molten metal in conjunction with the machine of Fig. 1.

Fig. 3 is a longitudinal section, partly in elevation, of the machine of Fig. 1.

Fig. 4 is a fragmentary horizontal sectional .15

view of part of the machine of Fig. 1 showing the structure of the compound hydraulic cylinders.

Fig. 5 is a diagram showing the hydraulic operating circuit for the machine of Fig. 1.

Fig. 6 is a diagram and face view of the barrel of the machine of Fig. 1 showing the circuit for electrical heating of slugs fed into the machine.

Fig. 7 is a detailed fragmentary view, in hori- 4 holders may be heated by coils 23. Lugs 28 and 39 are also heated.

In case the machine is to be used for pressure molding from molten metals or from mushy freezing material, barrel 26 may be removed and the pressure chamber insert may be provided with a molten metal inlet 3!, as shown in Fig. 2,

and as will later be described in conjunction with Fig. 15.

This completes the description of the gross structure as shown in Figs. 1, 2, and 3, and a detailed description of composite hydraulic cylinder [0 only will next be given, it being understood that composite cylinders IQ and H! are fundamentally identical. The parts of cylinder will hereafter be referred to in prime numbcrs corresponding to the numbers of the parts zontal section, of the relationship of the barrel,

pressure chamber, and mold of the machine of Figs. 1 and 3.

-Figs. 8, 9 and 10 are diagrammatic views showing how the residual metal is removed from the pressure chamber.

Fig. 11 is a diagram taken from the photomicrograph of the slug material. Fig. 12 is a diagram drawn from the photomicrograph of the finished molding.

. Figs. 13 and 14 are sectional views of an altermodified to operate on molten metal for pressure mold casting.

Referring to the figures, and particularly to Figs. 1,, 2 and 3 for the gross structure of one form of, machine capable of performing my method, a base I of heavy construction supports,

ateach end of the machine, cylinder blocks 2 and 4. Cylinder blocks 2 and 4 are tied together across the top of the machine by a tie rod 5 passing through a pressure block 6 rising from the base and positioned between the two cylinder blocks 2 and 4.

.In cylinder block 2 is positioned a dual hydraulic cylinder 10 having main piston 'l I projecting therefrom and directed toward one side of pressure block 6. In cylinder block 4 a similar cylinder I0 is provided having a main piston l I projecting therefrom and bearing against aslide block 15 sliding in guideways l6 forming apart of base I. An axle I1 is provided bridging I the gap between cylinder block 2 and pressure block 6, this axle being placed at one side of the center line of the machine and serving to journal a cylindrical barrel. 20 having a plurality of slug bores 2! therein. Pressure block 6 is aperturedto'line with the axis of the main piston ll for the insertion of a pressure chamberinsert, this insert being more fully described later. On the other side of pressure block 6 is positioned a pair of swinging die holders 22, each die holder being laterally rotatable on tie rod 5. Die holders 2 2.serve to hold die halves 25 laterally, and die holder's22 have angular faced locking lugs 26 and 21 thereon, which engage complementary shouders 28 on pressure block 6 and movable and complementary locking lugs 30 on the front face of sliding block 45 respectively. These die of cylinder I'll. V

In Fig. 4 I have shown in detail composite cylinder it as it is seen in horizontal section. Cylinder block 2 is bored out and the cylinder lil inserted therein and held by bolts 32, this.

cylinder being provided with an open end hearing 35 accommodating main piston 1!. This main piston H is provided with a piston head 31 operating in the head space 39 of cylinder Ii); The cylinder head MB of cylinder 10 is provided with a closed end bearing il, this end bearing 'fitting a hollow axial rod 42 extending entirely through the piston head 3's in piston head bearing 43, then into a secondary piston chamber 45 in piston I I, there to be attached to a secondary piston 45. Bod 32 is then continued through the remainder of chamber 45, through main piston end bearing d8 to project outside of piston H for purposes as will be hereinafter set forth. The front face 50 of piston H is so machined as to take various extensions as may be desired, and the inner end of rod 42 is pro-v vided with threads 5| as shown in Figs. 8, 9, and 10, so that the inner end may be plugged if desired with a proper tip, or may be left open to carry fluids or tubes, as will be explained later.

The main piston is to be controlled hydraulically, hence piston space 39 is provided with a-- hydraulic control bore 52 at one end thereof and a smaller bore 53 at the other end, for the passage of-a hydraulic fluid such as oil into and out of the head space 39 on each side ofpiston head 31. Secondary piston chamber 35 is provided with a fluid conduit 55 opening on one side of piston 46 and a fluid conduit 55 opening on the other side of piston 46, these conduits running in main piston H and terminating near the end thereof in connections for flexible pipe. Themain piston ll maybe progressed hydraulically along cylinder ID as desired, carrying with it piston 46 and rod 42. At the same time, however, piston 46 .may be controlled as to its position within the main piston H by hydraulic pressure. Thus I am able to obtain a differential action as between the main piston II and the rod 42 for various purposes, as will be described later.

I will now describe the machine as set up .for the making 'of molded-extrusionsas shown in Figs. 3 and '7, Fig. 7 being an enlargement of the portion of Fig. 3 having to do with the loading.

and extruding chambers of the device.

As previously described, rotating barrel 20 is provided with a purality of slug recesses 2L.v

Each slug recess is bored in a slug recess insert 60, each insert being electrically heated by heatlng coils. 6L Each insert is also providedwith a. qeg we Fie d... h r .si s .163 t ese;

ast ma brushes forming the termini of, the. related heat ing. coil I BI. The brushes: extend. outwardly and, as .the ,barrel,20. is rotated; the short brush con tactsashort brush segment 65, andthe long, brushescontact,inorder, outer. segments 06', 61, and 68', as the barrelis. rotated clockwiseiasseen in Fig. 6.. By, changing, the energization oflse y mentstt fil, and; 68. from apowersource 09, by theuseof resistors. I0, the temperature. of.v the slugs when. placed in the slugchamberscan, be, accurately controlledlduring feeding oi. theslugs.

Each insert.60 is providedwith. a. conedend'II engaging a, complementary surface. on apressure. insert I2"mounted' in pressure blocks 6.. pressureinsert 12 is provided with apressure chamber'l3 of the size of the slug chambers.2l,

and the chambers are coextensive whenregia. tered. Pressure insertIZisalsoheated by pressure,insertheatingcoil'IS.

Slugs are. transferred from, a. slug. recess .2 I to. the pressure recess I3 by extension I6 attached to the outer end 50 of piston II,,this attachment being hollow for the passage of rod 42, andprovided also, witha restricted. aperture I1 on.t,he end thereof, through which. a plug projection I8 may pass, this plug projection being. screwedin the endof rod 42., The outlet end of pressure chamber I3 is provided with a throat 80'of. genf erally Venturi shape, though, for efiicient operation. shouldipreferably be comprised of accns. tour on the order of that shown in Fig. 13,wherein the material'passing through is subjected to two or more squeezing actions, the small endloi throat 80 registering, under normal conditions. with cutofiapertures in cutoff plates. 84 and .85. Oneofthese cutoff plates 85. is vertically movableby a hydrauliccylinder system 86 as shown in Fig. 3; Plate 85 may be moved downwardly so that aperture 82 will register with a knockout piston 81 operating in' knockout'cylinderl 88 hy draulically controlled; Die plates 25 are made to have an inlet opening 90' registering with the apertures in thecutoff plates so that'metalpassing through throat 80 will flow into die space 9|. Referring now to Fig. 5 fora description of the hydraulic control formy device. In this figure which is diagrammatic only the auxiliary pistons 46 and 46 have been shown as separated from the main pistons. II and II' for clarity of illustration. A maintank I00 isprcvided'with a main pump A, pumping hydraulic-fluid such as-oil into an accumulatorcylinderIOI. The accumulator cylindercarries an accumulator piston I02 which, when moved upwardly byoil in" cylinder IOI, moves a weight I03 upwardly and the control of a main valve I I0 and a;main"-sump line III leadsfrom valve IIO back to maintank- Inasmuch as I may not desire to utilize, the high pressure fluid for preliminarymovements: of the pistons, I provide an auxiliary'control sys-.

tem comprising pump B pumping fluid from anv auxiliarytank II2 throughcontrol lines H5, IIIi,

and I I1.

Pressure .from line I I1 is led through. valve I It to bore 53 in cylinder I0, and also through valve I08 to either side of piston II, as desired. Thusi piston I I. may have accumulator pressure'on one side thereof. and control. pressure. iromopumpfiuorg the other side; ,whcreaapiston. I I. usesronlz pump B pressure for movement thereoti. How evenpistorr II maybezcontrolledby the accumulator itadesirablea Therauxiliary pistons 46 :and 40' are controlled:v bYgauXiliaryvalves-I IIleand I I8 respectively under:-

the-.messure-appliedtopiston I I canberegulated;

for. extrusion: of. different. materials without. changing-.the constants .of. the accumulator; 1111181 II Fla also supplies cutoff; cylinder 86, and knocks out cylindertfl under the valve.;control.i

It; will be obvious; from; the. brief description.-. given of; the hydraulic systemthat manyyof thee controlvalvcsmay, if desired, beinterlinked and;

operated. manually or automatically to follow as.

predetermined. cycle,

Having. thus described how the pistons: maybe operated I will nowproceed to describe the;oper-.--

ation of. the-machine as set up for making 8%..

simple. moldedeextrusion. In this case the die v blocksg25 areplaced together after a moldedeexetrusion .has been discharged, and enclosedbydie;

holders. 22. In order thatthese die holdersbe free to. discharge. the previous. forging, sliding,

block. I5'has been retracted by operationoiimainr piston. II, and the die holders 22 have been moved alongtie rod 5 to free locking lugs. 20

fromshoulders 28. After the. die is closed and.

'the i die. holders closed thereon, sliding. block.

I5. isthen moved toward pressure block 6 by'the use oflvalve I08 until the die holders 22 are firmlyv locked in position, with the opening of the die:

adjacent'to the openings in cutofi. plates 84. and.

85. Thev latter, have been moved to register by the use of. hydraulic cylinder 86 which isalso. operated. from auxiliary pump B. Valve I08 is closed, thus providinga hydraulic lock for piston II. The slugrecesses are loaded and thebarrel. is. rotated, with the slugs in recesses 2I being. heated electrically as, the barrel is rotated with.v a finaland high heat just prior to the rotation. of the brushes off of segments and 68, so. that. the preheated" slugmay, then be. brought intov registry, wlthpressurechamber I3. At thisti-ma the main piston II is operated by, useof. valve. IIO to force the. preheated slug outofltheslug recess,2'I ihtopressurechamber I3 and through throat.80..

H wev nthe prehe ing of'the slug whichhas...

taken place in barrel 20 and theheating which. is also occurring in. thepressurechamber I3 is. not, necessarily sufficiently highto bring the slug. into either. amushy-or molten condition. When... however, the slug. is forced againstthroat 80,.

' heatis developedat this point. This additional.

heat, is. suflicient to reduce the end. of the slug in thethroat to" a. mushy or plastic condition so that the metal will flow in a mushy, thick'condition; through the registering openings 'into the diecavity. The shape of the throat may be so regulated and designed that the heat developed at that point will never be suflicient-to bring the metal into a true molten condition, but only enough to maintain the metal sufficiently plastic topass through the openings into the die cavities. A variation in the ratio between the" orificeand the piston diameter will regulate-the. grainsize. anatemperature .of the mushy :maI ;e.-;

. 7 rial extruded into the cavity of the mold, to be upset therein. r

As the main piston through extension 16 is forcing the mushy slug material into the die cavity and as the cavity fills, the accumulator weight I03 is, of course,fallingand exerting high pressure on the face of extension 16, and because of its weight and velocity, is building upan in-- ertia for the final impact. As can be seen in Fig. 8, the interior piston 46 may be operated during the progression of the main piston to bring tip 18 mounted on rod 42 flush with the face of piston extension 16 so that as the extension 16 moves to force the slug out of the pressure chamber, the extension has in eifect a flat face presented to the slug. However, just as the extension I6 reaches its final position, registering with the beginning of throat 80 as shown in Fig. 9, rod 42 may beretracted so that a portion of the slug metal (plastic at this point) enters the hollow end of extension 16 to form a residual metal stem 200 which will remain attached to residual metal 20! which will remain in throat 80.

However, as the main piston travels forward and reaches the end of its stroke, the die cavity 91 will become full. Consequently no more mushy metal may be forced through throat 80 a coils 23 in the die holders, so that the metal the die blocks, after extrusion and at the time of the application of the extreme high pressure from accumulator I03, can be held at any temperature desired. I prefer to control this temperature so that just as the metal is about to solidify in the die cavity 9|, the high pressure be applied. The sudden application of the extremely high pressure from the accumulator, together with the Working of the metal in the throat 80, completely changes the character of the extruded material, and makes the grain structure and physical properties much more comparable to a forging than to a casting, as will be explained more in detail later.

It will .be noted that while the high pressure is applied only by piston II, this pressure, through the die blocks, is also applied to sliding block [5 and piston II. This piston being under a hy draulic look by closure of valve I08, piston ll therefore exerts a high pressure on valve I08, and

tosafeguard this valve, I apply through line 10'? the pressure of the accumulator to preventvalve breakdown and to balance the valve elements during the application of high pressure theretoQ As the metal in the'die cavity 9| is chilling, and while the throat metal is still plastic, plate 85' is moved downwardly by action of hydraulic the metal.

ing, to be taken out of the die cavity. At the same time the piston l I is retracted carrying with it the residual metal 200 and 2M as shown in Fig. 10. The portion 200 has, of course, been molded into threaded engagement with 'the threaded end of piston extension 16 and this threaded engagement is sufficient to break loose the portion 20! from its throat engagementas the extension is retracted. After the piston extension 16 has been retracted sufiiciently to bring the portions 200 and 2M out into the open on the cylinder l0 side of barrel 20, the portions 200 and ZEJI are unscrewed from theend of the piston extension. j

A somewhat modified way of accomplishing the removal of metal portions 200 and 20I from the venturi is to employ a circular groove in lieu of the threads for effecting a grip on this metal and then employing a rod like the rod 42 as a knockout rod to force the plug out by shearing it from the bead which formed in the aforementioned circular groove.

Each slug may hold enough metal to make many parts. Also, some metals permit the reuse of residual metal by leaving it in the chambers and extruding it on the next cycle through the orifice into the mold. Thus a perfect homogeneous joint is the result.

'When the slug metal is used up, barrel 20 is then indexed to bring the next pro-heated slug again into registry, the die reassembled, placed in position, and the cycle repeated.

When the extruded, refined and mushy plastic material moves from the reducing orifice into the cavity of the mold, it moves to the opposite end of the cavity and is upset there. 'In other words, the metal actually changes shape at the far end of the mold and is formed until its di-' ameter and shape is telescoped to fit the exact shape of the cavity. This change in shape is important because it provides a definite further working of the metal inside of the cavity during filling thereof, this working taking place while the temperature is being reduced by chilling of The grain is then further worked by the impact pressure and the end result is a fine grained article, uniform from surface to surface.

Because the mushy material going into the mold is solid and viscous it expels the air in the mold very much like a piston pushes oil out of a cylinder. Porosity cannot occur under these conditions. The metal is not broken 'up or sprayed, as it might be if the liquid were to be forced in quickly. The air is therefore pushed out of the mold without mixing with the incoming metal in any manner.

I have found, for example, using slugs of beryllium copper, that by using a 5 second extrusion time with 60,000 pounds extrusion pressure and a final forging pressure of from 200,000 to 225,000 pounds per square inch, molded-extrusions can be made which have many of the desirable charaoteristics of drop forgings, and which are in no way comparable to die castings made of the same material in the usual manner, but which compare in physical properties to the same metal extruded in continuous pieces by the cold extrusion method common to the industry; however, entirely without flow lines or slip planes or concentrated' working at points where shape is most complicated insectional change.

The process as thus described, and the product which'is produced, differradicallyfrom die castling,..althoug'h it .will .betobvious .by inspectioncf the machine that pressure-mold casting from molten or mushymetal can .beaccomplished when temperaturesand pressure are adjusted forsuch castings, and .even .in this case a finalfforging pressure greatly improves the casting. Themachine will handle materials whichdo not die cast readily, but which can be pre-heated and thereafter extruded in plastic mushy forminto the die to a desired shape in a single operation.

When my method is applied to pressure-molding, using molten or mushy metal, the die cavity is in a slightly different position, this position preventing any air. mixture with the incoming material, as shown in Fig. 15. Here it will be seen .thatthe charge of molten or mushy metal placed in fitting 3! shown in Fig. 2, .is to be .iorcedinto the die. Inthis case the die parts .22 are elevated above the level of the liquid andare heated. The molten or mushy material is then "forced slowly into the dieby piston extension 76 through a large filling gate, as throat 80 is removed. There would be no value here of forcing a molten metal through a reducing orifice, as the material is already at or above the plastic temperature. The molten metal is then slowlyforced "upwardly in the die, forcin the air out of the die joint or a vent, ahead of it, until the die is full, whereupon the final impact pressure is applied to the metal in the mold in exactly the same manner as has been previously described. The timing of the filling 'ofthe die and heating of the dieis as before arranged so that the final impact pressure will be applied just as the metal freezes from the plastic state. It has been'found that even with this type of molding, the metal is worked in the die itself and particularly'when multiple dies are used having restricted "connections therebetween which work the metal as it passes therethrough in the mushy state during chilling. The metal is under such great pressure at all times afterpassing through the throat that the usual gas that comes from a melted metal does not have any opportunityto enlarge. "The operation is done swiftly and the final pressure applied to the material provides a forging impact to the metal just as it is passing from a mushyplastic to a solid state. This impact molds the part even to the extent of giving threaded impressions, engraving or molding around pins or cores "for holes. Thus it can clearly be seen that my method is applicable, not only for use on special machines, as illustrated, but also may be readily adapted for use on ordinary die casting machines, by appropriately heating and position ing the die, and by accurate control of pressures, and timing the application of these'pressures.

The change in the grain structure is diagrammatically represented inFigs. 11 and 12. Fig. 11 is takenfrom a, photomicrograph of the cast slug material before it has been passed through the machine, and Fig. 12 is a representation of the same material as it appears under the microscope after having been fabricated into a moldedextrusion after the method justabove described. It can readily be seen that the grain structure has-completely changed and that the grain of the final product is extremely fine and uniform, givingcharacteristics to the product which ismuch more like a drop forging or cold extrusion Ithan like-a casting, except, of course, thelack of flow lines and slip planes which areconsidered as imperfections in forgings and extrusions.

.The increase in the temperature caused by the .plasticizing temperature.

-does: not cause oxides and hasa tendency toward 'closer wedding or hot workingofggrain structure while the metalis being reduced in diameter by extrusion.

.Barrel 20, which holds the metal slugs before they are passed into the machine may, of course, be automatically indexed. During the regular cycle 'ofoperation of the machine, this barrel will preheat each slug to exactly the same temperature. The function of the preheating cycle,

however, is not merely the preparation of the slug material for presentation to the pressure chamber 13 in order that the time of stay in pressure chamber 13 may be reduced. It is also for the purpose of giving the slugs a heat treatment which may, if desired, be of even higher temperature than the temperature of the slug when it is being forced through the pressure chamber. The preheating of the slugs therefore is important in determining the type of grain structure which isattained inthe final forging. The

plete heat treatment. Because there are no concentrated stresses created within the structure of the part caused by slip planes and flow lines and shrinkage, there isno warpage or distortion resulting from this type of heat treatment.

Inasmuch as the metal before quenching is plastic, accurate control of the proper temperatures can be obtained by pressure regulation, without the use 'of thermometers. The proper quenching temperatures can be established by adjustment for any of *the alloys used. in the preheating stage, and by changing the shape and size of the throat 8G to give the required The temperature of the :mold can be controlledand changed as desired by heatingandcooling of the mold parts. It should also be noted that the working and compressing of the metal .in the mold before chilling .or .quenching completely eliminates warping of theflnal forging. The high pressure applied :tothe metal in thedie works'the metal right ,up to andpreferably below the point of freezing. This eliminates most of the-need for shrinkage allowances .in machining the cavity in the die. The metal is always under enough pressure while .it is. chilling to overcome this very usual fault of the common die-casting procedures. Thus, my method and machine permit very raccurate parts to be molded to the very closest tolerances. The treatment is also extremely uniform because the operation of the machine "can be made wholly automatic in operation-and bemadeto operate under ,a regular cycle. Furthermore, parts made by my process, as described herein, may be heat-treated either simultaneously with orrfollowing the fabrication without substantial distortion.

.In Figs. ,1-3:and;14= is shown diagrammatically a modification ofJmy invention for use in making hollow .andcontinuous molded extrusions such as tubular sections with bosses and details added. In-this case,ihollow.rod42 of piston ll iszprojected through the sliding block l5, through the die block and the die space 9| to form a core 'or mandrel therein. In this respect it will be noted that the die and mandrel arrangement so set up is ideally adapted for the production of tubing or, by using a die properly cut, for the production of rifle barrels, for example. In this case a hollow slug is used and the end of rod 42 of piston I! is provided with a hollow swollen tip 2m, and cutoff plates 84 and 85 are removed. Tip 2"! passes through the center of the slug and has an end recess 2 therein registering with the end of hollow tube 42' of piston ll'. As no cutoff plates 84 and 85 are used, and while the metal is still in plastic condition, rod 42 is progressed toward the small end of the throat to pinch oif the metal, leaving the die metal completely free from the residual metal 29! in the throat 80. Inasmuch as the end of tip 2I0 is larger than the diameter of rod 42, the throat metal will be retracted with the retraction of the piston extension it, thus freeing the molded extrusion and providing a means for removing the throat metal. The tip 2 I ll may then be unscrewed from rod 42 and the metal 2! removed. However, the arrangement shown in Fig. 13 does more than just cut off the throat metal from the die metal, because the end of rod 42' is maintained in exactly central relationship in the die during the solidfying of the die metal. The end of tip 2|!) also serves to' evenly divide the metal flow as the plastic material passes into the die. It should also be noted that in this case the hollow portions of rods 42 and 42 are connected together, and the conduit thus formed may be utilized to carry air, gas or liquid through the die and throat material so that the core may be rapidly cooled or quenched after the final impact and setting has taken place to facilitate removing the core. or for other purposes.

The device, therefore, as just described may be utilized for making long tubular materials and is, as stated above, ideally satisfactory for the production of rifle barrels, together with all exterior conformations thereof, all in one piece. I have found that beryllium-copper rifle barrels may be formed in this manner, which require very little finishing, and that the bore thereof,

as produced by the mandrel rod 42', is sufficiently accurate to need only a final sizing and rifiing with a broach.

This method of continuous extrusion-molding is also adaptable to making wing beams or spar caps for airplane structuresuch as'are now made from conventional extruded shapes, and which require hundreds of hours of machine wo k to mill oiT the various changes in section to remove the material to the proper taper for effecting a saving in weight.

After the tubular forging has been separated from the throat material and the throat material retracted, the mandrel rod 42' may then be retracted through the die by applying pressure to piston 46', the piston I I retracted, and the forging can be removed.

In case a tubular core is to be left in the tubular molding I then prefer to utilize cutoff plates 84 and 85, to remove plug 11 from rod 42 and run the tubular core through the interior of rod42,"

through the die and then into rod 42'. This core then remains in place in the molded article, the tube being cut off by the shearing action of plates 84 and 85. For each new extrusion the core may be fed into the die through rod 42, either auto-- matically or by hand.

The same machine with various temperature dation of the molded material.

adjustments can accommodate all of the various results therein described on various types of gun or ordnance parts, such as gun barrels, brackets, bolts, etc., and also all manner of fittings for machines, automobiles, airplanes, boats of any description, as well as small apparatus or tools, surgical instruments, presses, motors, or manufacturing machines and electrical apparatus. The manufacture of shells and shell cases can be reduced in cost by the machine.

This machine, while it is described as hand controlled in operation, can be as easily made full or semi-automatic, and still accomplish the complete cycle of operation as required to execute the fabrication of the part as tooled.

My machine can handle pig material, cast or wrought bar, or pressed powder, or can be adapted for either pressed, molded, or cast blanks. It can also use cutout pieces of metal or material that has suitable specifications to permit the proper operation of the machine. When materials to be pressure-forged are molten, pressures can be reduced as compared with those required for extruding and molding plastic material. My machine and method is practical for. all materials that are converted to a mushy plastic up to 2,000. F. which is the limitof the materials used in the construction of the equipment.

Materials capable of being reduced to plastic form, include the so-called organic plastics, as well as metals, in powdered, solid or mushy form capable of being plasticized by heat and pressure and thereafter molded. Organic plastics can be molded, following the teachings given above, except of course, that the temperatures required are. lower than those for handling metals. these temperatures being known as characteristics of the particular materials used.

Inasmuch as the organic plastics, either of pressure-setting type. or the thermo-setting type, are usually in powder form, the first step in making a molded extrusion of these materials by my method and with my machine, is to press these materials into a small bar or briquet of approximately the size required for filling the cavity of the mold utilized. This primary assembly of the powdered material into bar or briquet places the material into condition to be inserted into the pressure chamber 13 in position to be pushed forward by extension 42 through throat into the cavity of the mold, following which operation, the pressure'which has been built up by the inertia of the falling accumulator weight is applied to the material in the mold to complete the consoli- One important advantage of this process, in molding the organic plastics is the generation of heat in the crosssection of the material by pressure and working, as it passes through throat 80. This reduces the time for adding heat to the outside of the mold, without waiting for long periods for the molded plastic material to absorb heat, expand and setafter it has been forced into the mold. Such a process therefore is particularly applicable to the thermosetting plastic materials. The throat 80 can be heated to a much lower temperature than is required for heating the material in other processes.

The extreme pressure, forcing the material through the throat, with a reduction of cross. sectional area, generates sufflcient heat to cause the powdered or flaked material to become soft and heated to the proper temperature to be forced into the cavity of the mold and upset therein to fill the cavity with this soft or plastic material,

towel-mo rdinarily,=withvethermosetting' plasticsiitiis'zicc- 'essary to permitthe material to heatl inithec mold fora relatively long period of time tobringlabout the proper condition: of thexplastic material and :tocause i it to set and chill},properlyibeforeiits removal. The plastic materials-themselvesare heat .throat 80, there is nodoss of 'timeiirr waiting for :the molded material to saturate with :sufilcientheat to change the properties as .required wfor proper setting.

Because of the heating "occurringat throat- 811 the organictplasticmaterial can'be handled: muchmore rapidly and -1eiliciently 1 by the method and machine described-. above than bywordinary mold ing-Processes.

In case the extrusioncycle 'caniberspeeded beyond the time needed for the article to cure in the mold,"a' rotating. mold holder similar to the rotating slug-holder may be provided, so that -l as one mold isfille'd, -the'"moldlholder can be ro-v tated similarly to the rotation .of slug-holder 20,

anda new'mold filled while thepreviously filled molds are chilling. In this manner the loss of machine timewill beminimi'zed; and the productioniof' molded plastics will'begreatly speeded.

Microscopic examination of organic rplastics molded aszjust above described disclosesithat the compression-occurring in throat 80, besides im parting an elevated temperatureof thei material, also bringsabout a pressure bonding otthepar ticles in addition to the bond supplied byihe'at and expansion. Because of this-ijcharacteristic, articles of organic ,plastics made as just above described have been "found "to "be denser, and henc'e stronger and more uniform, than are articles formed from organic plastics und'er the more usual. methods.

This method broadens the already large field of materials that can be used in making articles a of plastics and enables diflicult types of plastics to become compartively easy to handle.

I claim:

1. A molding machine comprising means for holding a mold, a mold supported thereby and having an opening thereto for the introduction of moldable material, a pressure chamber open at one end and terminating at its other end in a Venturi-shaped throat adjacent said opening,

a barrel rotatably mounted on said machine and having a plurality of slug receivable openings circularly disposed on a radius from said barrel mounting to bring said openings successively into alignment with the open end.- of said pressure chamber upon rotation of said barrel, and piston means in alignment with said pressure chamber and successively aligning slug receivable openings and having a piston travel approaching said Venturi-shaped throat.

2. A molding machine comprising means for holding a mold, a mold supported thereby and having an opening thereto for the introduction or moldable material, a pressure chamber open at one end and terminating at its other enddn a discharge opening to said mold, a barrel rotatably mounted on said machine and having a plurality of slug receivable inserts circularly disposed on a radius from said barrel mounting to bring said inserts successively into alignment with the open end of said pressure chamber upon will 'irotat-ion cof': said "barrel, iafheatingz coil surrounding each slug receivablezinsertiandTterminating in a pair of brushes, "a ilcontact f'disposed'iin :the path of :tmovement of tone of said brushes, :a

"series of contacts To'f increasingly :higher :potential ivith respect to said first "contact a'n'd"disposed in Zthe path of movement of said other brush, and: piston'means in-ali'gnment with said pressure chamber and "successively aligning inserts and having a piston Ltravel approaching said discharge opening.

:3. "A :molding machine comprising means for holding 2a: mold; a mold supported t'hereby and having "an'op'ening thereto for the introduction .of :mold'able material; a :chamber for receiving "such :material prior to introduction into said "shaped throat Fadja'cent -said opening; .a piston disposed rin :alignment with said chamber and said opening to said moldifor movement into'said chambenfsaid-piston having an axial bore therein, ::and Pa iro'd iin said bore terminating beyond the work fend :of :said piston in an outwardly flaring "tip having a countersink :at the Ifront end thereof, :a 'mandrel extending through rsaid mold :and "venturi sha'ped throat into said chamber, said ioutwardly flaringtip being adapted :to receiver saidimandrel in "said countersink during theforward'stroke of said pistonland engage said Venturi-shaped fthroataiollowing' the termination ofvsaidpiston: strokarand: meansifor causing'sai'd tip toreceive'saidfmandreLandengage said Venturi-shaped throat following i movement 6f said piston into said chamber.

24. 1A molding machine comprising means for holding "a mold; "az'mold "supported thereby and having an opening itheretoio'r "the introduction of moldable imaterial; a chamber for receiving such material prior to introduction "into said mold, :said chamber 'iterminatin'g in 'a Venturishaped \throat adjacent said opening; a piston disposed iin alignment with said "chamber and said opening to said :mold for movernent into said chamber, said piston having an axial bore therethrough, and a hollow rod in said bore terminating beyond the work end of said piston in an outwardly flaring tip having a cylindrical countersink at the front end thereof; a hollow tubular mandrel extending through said mold and Venturi-shaped throat into said chamber, said outwardly flaring tip being adapted to receive said mandrel in said countersink during the forward stroke of said piston and engage said Venturi-shaped throat following the terminationof said piston stroke, and means for causing said tip to receive said mandrel during the forward stroke of said piston and engage said Venturi-shaped throat following completion of the forward stroke of said piston into said chamber.

5. In a molding machine comprising means for holding a mold having an opening thereto for the introduction of moldable material; a chamber for receiving such material prior to introduction thereof into such mold, said chamber termi mating in a discharge opening to such mold and a piston disposed in alignment with said chamber for movement into said chamber; means for producing a forward stroke of said piston into said chamber and an upsetting pressure at the completion of such stroke, said means including an accumulator cylinder having a valve controlled hydraulic connection to said piston, means for introducing a liquid into said accumulator.

lator cylinder supported on said liquid, when said liquid is introduced therein.

6. In a moldingmachine comprising means for holding a mold, a mold supported thereby and having an opening thereto for the introduction of moldable material, a chamber for receiving such material prior to introduction thereo'f into said mold, said chamber terminating in a Venturi-shaped throat adjacent said opening and a piston disposed in alignment with said chamber for movement into said chamber; means for producing a forward stroke of said piston into said chamber and an upsetting pressure at the completion of such stroke, said means including an accumulator cylinder having a valve controlled hydraulic connection to said piston, means for introducing a liquid into said accumulator cylinder, and a weighted piston in said accumulator cylinder supported on said liquid, when said liquid is introduced therein.

7. A molding machine comprising a mold having an opening thereto for the introduction of moldable material; a chamber for receiving such material prior to introduction thereof into said mold; said chamber terminating adjacent said opening; a piston disposed in alignment with said chamber for movement into said chamber, said piston having a bore axially therethrough-grooved at the work end of said piston, and a rod in said bore and normally terminating adjacent the work end of said piston; and means for retracting said rod into said piston as the piston approaches the end of its work stroke in said charmber.

8. A molding machine comprising means for holding a mold; a mold supported thereby and having an opening thereto for the introduction of moldable material; a chamber for receiving such material prior to introduction thereof into said mold; said chamber terminating in a-throat adjacent said opening; a piston disposed in align-- ment with said chamber and said opening to said mold for movement into said chamber, said pis- '16 ton having a bore axially therethrough threaded at the work end of said piston, and a rod in said bore and normally terminating adjacent the work end of said piston; and means for retracting said rod into said piston as the piston approaches the end of its work stroke in said chamber.

9. A molding machine comprising means for holding a. mold; a mold supported thereby and having an opening thereto for the introduction of moldable material; a chamber for receiving such material prior to introduction thereof into said mold, said chamber terminating in a Venturi-shaped throat adjacent said opening; a piston disposed in alignment with said chamber and said'opening to said mold for movement into said chamber, said piston having a bore axially therethrough threaded at the work end of said piston, and a rod in said bore and normally terminating coextensively with the work end of said piston; and means for retracting said rod into said piston as the piston approaches the end of its work stroke in said chamber.

CHARLES C. MISFELDT.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Great Britain Nov. 15, 1934 

